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Purpose
To provide work and process controls to achieve
high level of leak tightness integrity to properly
designed Bolted Flange Joint Assemblies
Uniform use of this procedure by and other
Contractor personnel is expected to result in aero incidence rate of flange leaks
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SCOPEThis process is applicable to flanged !oint assemblies for"
#iping
$alves
%eactors
$essels
&rums
'xchangers
Boilers
Coalescers
and other e(uipment using flanged !oints administered at
all !obsites
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SCOPE
This process is to be implemented in con!unction
with the approved design standards)
This process is applicable to the field offices thatpurchase* receive* field fabricate* inventory*
install* erect* and inspect piping and piping
related components)
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SCOPE
&eficiencies identified during in+process monitoring andfinal inspections* shall be documented and tracked in
accordance with the individual site practices for Control
of Deficient Items.
Any aboveground piping within the !urisdiction of A,-'
,ection . #ower Boilers* and A,-' ,ection B/0)0
#ower #iping* and any work related to A,-' ,ection
$... $essels* shall be executed in accordance with the
A,-' -anual for A,-' Code Construction andadditional re(uirements stated in the Bolt Flange Joint
Assembly procedure)
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Definitions
Fasteners 1 all bolting* studs* nuts* and washersused in the assembly of flanged !oints)
Flange Maps are isometrics drawings* sketches*
e(uipment drawings* and2or #3.&4s that 5map6
flange locations and identifies each flange
connection with uni(ue numbers)
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DefinitionsInspection and Test Plan (ITP) is a document that
outlines examination* inspection* and2or hold points* and
witness points activities)
Flange Tightening Method is used to tighten flanged
connections as pre+determined and specified on the
flange maps) The method used can be indicated on
flange tags so that the relevant information is
communicated to persons directly responsible for the
assembly of flanged connections)
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Training
.n general* all personnel with duties associatedwith the bolted flanged !oint assembly program
are to receive training) All training is to be
documented)
The BFJ Progra! "ualit# Training Matri$ lists
all affected personnel and their corresponding
level of needed training)
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%esponsibilitiesSite Manager 8,-9 ensures that the re(uirements of this :ork
#rocess are properly implemented)
Superintendents are responsible for the overall (uality of work
performed by maintenance and construction personnel for
their assigned area8s9)
Site "ualit# Control Manager 87C-9 manages the 7uality
Control functions for the pro!ect* provide oversight* and direct
the work of the site 7C.4s)
The 7C- addresses any deficiencies in the BFJA program
with appropriate personnel to assure continued compliance
with the program)
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%esponsibilities
Piping Fore!an ( PF ) is responsible for"
Understanding the work scope and re(uirements of this
process
Adhering to pro!ect drawings and specifications
-aintaining good workmanship and fulfilling all (uality
re(uirements of the work and targeting punch+list itemsassociated with completed work activities
Assigning trained personnel to assemble flanged !oint
connections
Arranging all re(uired work permits* tools* e(uipment*scaffolding* and consumable material for the work activities
Coordinating and scheduling work activities based on pro!ect
schedule re(uirements
'xamining and verifying BFJA4s in accordance with the .T#4s
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%e(uirements'or Process
All materials and workmanship shall fully comply with the designdrawings* Client specifications* and applicable Codes and
,tandards)
Field changes to design documents shall not be performed without
prior written approval from the Client)
All measuring and test e(uipment used during the installation*
testing* and verification of piping systems shall meet the
re(uirements of T.; procedure -T'+0* Control of -easuring and
Test '(uipment)
All material specifications and applied tightening method information
must be disseminated to personnel assigned to flange mapping)
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Preplanning ctiities
#re+activity construction meetings should be held to
finalie the scope of activities prior to the
commencement of work or unit blinding)
A review of the .nspection and Test #lan for BFJA4s
and referenced documents shall be performed by the
7C-) The re(uired 7C and Client
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#replanning Activities
#iping ,upervision8#,9 shall maintain a full
understanding of the work scope and installation criteria)
The #,* working with the 7uality Control personnel* shall
develop the leak test program as per the procedure to
ensure that all piping is tested is in accordance with the
pro!ect specifications)
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'or Preparation*Initiation
Assigned personnel will have the responsibility of providing a blind
list and of hanging of blind tags at all blind locations) This will bedone prior to the hanging of flange tightening tags by craft
personnel)
Applicable personnel will have the responsibility for generating
flange tightening tag lists for all flanges to be disturbed during
each2any activity 8i)e)* Turn+Around* %outine -aintenance* Capital#ro!ect* etc)9) This list will be maintained and appended should the
scope of the activity be advanced)
All disturbed flanges will be identified using a uni(ue numbering
system) This system numbering will be e(uipment* unit outage*
and2or pro!ect specific) The determination of the tightening methods to be employed shall
be indicated on the Flange Tags)
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Flange Tag Preparation and +anging At initial execution of work* the company will issue and hang initial
Flange Tightening Tags on all flanges2line breaks to be loosenedand then tightened)
Flange Tightening Tags are to be filled out and installed on all
flange2line breaks and when blinds are installed)
'ach flange will have an individual tag 5Uni(uely numbered6)
Flange tags shall be initiated and attached to affected BFJA4s in
accordance with the flange maps)
Flange Tightening Tags are to be filled out and hung as each flange
connection is made up and completed) These tags will be attached
to the flange connection using electrical tie wraps or bailing wire)
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The same process is to be followed throughout the final removal
and final assembly of the connection)
The Flange Tightening Tags will be removed only by 7C after the
final removal of the blinds and2or final flange make up)
All revisions or additional of work are to be treated as Field Changes
and will be added only as additional work once approved by
appropriate management personnel) =nce approved and planned*
7A27C &epartment shall be notified of the work* prior to execution*and prepare Flange Tightening Tags and update the flange logs for
the flanges2line break affected)
Flange Tag #reparation and
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Material +andling and Storage
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-echanical Joints
Flanged valves shall be checked for thefollowing" Check* globe* and control valves are installed with
indicated flow in the correct direction as indicated on
the #3.& -anufacturer4s name tag description agrees with
stock code number 8if used9* description* and trim)
&o not rely on warehouse tag)
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'or Process Flo, and
Docu!entation All BFJA4s shall be tightened using the method assigned)
As flanges are tightened* the responsible craftsmen will completethe re(uired entries on the tag* sign and date* and inform his
appropriate foreman or supervisor of the connection completion)
The foreman or his designee will then check the flange for proper
gasket* proper type of bolting 8i)e)* nuts and studs9* proper flange
alignment* and bolt tightness) .f all is correct* the foreman ordesignee will sign the flange tag and notify the 7C representative
that the flange is ready for inspection)
7C will verify the flange installation is in accordance with the .T#)
:hen .T#4s re(uire witness or holds by the Client* the 7C inspector
shall make those notifications to Client) Upon final acceptance* the 7C .nspector will remove the Flange
Tightening Tag8s9 and turn them into the ,ite 7C -anager)
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Blinds All blinds installed on towers* drums* reactors* piping* etc) shallreceive Flange Tightening Tags) The installation of the Blinds shall
be documented in the designated area for Blind installation located
on the back side of the Flange Tightening Tag)
Flange Tightening Tags are not to be removed until the blinds have
been removed* the final flange is made up* and the actions
documented on the front of the tag as per the procedure)
Flange Tightening Tag tracking is to be kept by 7C in the masterelectronic >ine Break Tracking ,ystem) -anways are to be
included)
'or Process Flo, and
Docu!entation
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?@0
System requires Bolt/Nut Replacement ___Yes___No
#3.& Do)
FLANGE TIGHTENING TAG
F%=DT
UD.T"
'7U.#2.&"
&AT'"
C%AFT,-AD"
PRINT NAME
SIGNATURE/DATE
Foreman
PRINT NAME _____________________
,ignature
SIGNATURE/DATE
7uality Control
PRINT NAME
SIGNATURE/DATE
Final Flane !a"e up #ata
continue# $rom $ront si#e
B=>T ,#'C.F.CAT.=D"
B=>T, %'#>AC'&" E', D=
;A,'T ,#'C.F.CAT.=D"
.D,#'CT F>AD;' FAC'
E', D=
STENCIL/COMPANY
SIGNATURE/DATE
D': ;A,'T .D,TA>>'&
E', D= =$A> %.D; .D,#'CT'&
E', D=
STENCIL/COMPANY
SIGNATURE/DATEBelow is to be used only for blind installation
CRAFTSMAN ________________________
PRINT NAME
_______________________________ STENCIL/COMPANY
_______________________________
SIGNATURE/DATE
C=-#'T'DT #'%,=D
PRINT NAME ________________________________
STENCIL/COMPANY
________________________________
-A.DT'DADC' SIGNATURE/DATE
F=%-AD2,U#$)
PRINT NAME ________________________________ SIGNATURE/DATE
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At times Flange Tightening Tags become misplaced* the foreman or
,upervisor over this work will obtain a new tag from the 7C
&epartment) The new tag number will replace the missing tag
number and the new number added to the Flange -ap) This new
tag is to be attached to flanged connection) All (uality checks* suchas proper gasket* bolts* nuts* tor(ue tightness* etc) will following the
same work process as a new connection)
'or Process Flo, and
Docu!entation
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Flange Assembly #ractices
Preparation Bolts shall be checked for proper sie* length* and grade as per the
information provided on the flange tag) Bolts shall be clean and free
of damage)
'xisting bolts to be reused shall be clean* in good condition* and
undamaged 8nuts should run free on the bolt9) They shall beprepared for short+term storage using a rust preventing lubricant
and can only be re+used as per the Bolt .nspection and %e+Use
procedure)
Just prior to installation* bolt threads and bearing surface of nuts for
all bolting shall be coated with an anti+seie compound) ;askets shall be checked for sie* conformance to specifications*
damage* and cleanliness) All gaskets shall be compared with the
flange face to insure that the gasket seal area properly mates to the
flange face)
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Flange faces shall be thoroughly cleaned and the gasket surface
inspected for any defects) Burrs and rust shall be removed)
#articular attention shall be paid to the sealing surfaces for metal
gaskets such as the grooves in ring !oint flanges and to the 0GH
AA%< finished flanges) Any (uestionable flange faces shall bebrought to the attention of 7C in accordance with the BFJA .T#)
Alignment measurements shall be taken prior to flange assembly
8e)g) installing stud bolts9) Alignment tolerances of mating flanges
for #ipe to $essels or ,tationary '(uipment Doles* #ipe to #ipe*
and #ipe to .nline &evices shall be in accordance with thetolerances outlined in the Table --0)
Flange Assembly #ractices
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-aximum -isalignment Table --0
-I./ME/T DETI- M0IM1M PE%MISSIB-EMIS-I./ME/T OF F-/.ED JOI/TS2
I/3
D#, I 0G 0GI D#, I
GG
D#, G
$ertical bolt hole offset 02K 020L 020L
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sse!&l#
Bolt holes of mating flanges may be brought into initial alignment
using a spud wrench or other tool) The alignment tolerances
provided in Table --0 shall be recognied)
Flange 5makeup6 shall be done without the use of gasket sealing
compounds) The gasket shall be inserted* and centered between the flanges and
nuts hand tightened to hold the gasket in place) Assure the color
coding of spiral would gaskets) 8attachment J9 :hen flanged !oints
are in horiontal lines* gaskets without centering devices such as
ring !oint gaskets shall be lowered to the bolts for retention and thenraised into position)
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The remaining bolts and nuts shall be installed and hand tightenedwith the flange faces parallel) Care shall be taken to assure proper
seating and centering of the gasket within the allowable tolerances)
,nug tightening with a combination wrench prior to tensioning is
permitted on large flanges)
Bolts should be installed so that only one to three threads show pastthe nut on either side)
sse!&l#
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F.;U%' 0 1 B=>T T.;
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sse!&l#
Two diametrically opposite bolts shall betightened either simultaneously or in direct
se(uence)
Care shall be taken to prevent over+tightening
one side of the flange to prevent gasket crushing
or flange distortion* especially when tightening
flanges containing ring !oint* spiral wound* orsimilar type gaskets)
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.n the case of flanged !oints that re(uire controlled tor(uing* it isrecommended that initially two diametrically opposite bolts shall be
initially loaded utiliing tor(ue wrench tightened to GHN of the tor(ue
load value listed in the procedure* either simultaneously or in direct
se(uence)
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sse!&l#
:hen flanged !oints are assembled with hand wrenchesO the
se(uence in in the procedure shall be used with an effort to
approximate the tor(ue values)
.f flange !oints re(uire hydraulic tensioning* this work will be
performed by a subcontractor that specialies in controlled bolting
and with experience in hydraulic tensioning methods) ,pecific
re(uirements regarding the basic (ualifications of this contractor
and their work practices are detailed in the procedure)
After the flanged connection has been fully tightened with hand
wrenches* the !oint shall be inspected for uniform bolt loading by
wrench testing each bolt in the same se(uence listed until all bolts
are !udged to have the same level of tightness)
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=nce the flange !oint is assembled* the craftsman shall initial the
applicable examination entries on the flange tag and alert his
foreman or designee for verification of the BF>A) The foreman or
designee will verify the BFJA* initial the flange tag for acceptance*
and notify 7C for inspection All flange connections that re(uire controlled tor(uing or hydraulic
tensioning must be documented by the craftsperson) At a minimum
this documentation shall include the Control >oaded Flange
Connection &ata ,heet as seen in the procedure)
sse!&l#
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Final Co!pletion and Turnoer
Final Co!pletion and Turnoer
The ,ite 7C -anager or his designee will accumulate flange tagsand update the flange tags logs) Flange tags* flange tag maps* and
flange tag logs will become an integral component of document
turnover)
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Good Poor
Rotational
Skewed
Excessive Gap
Non Parallel
Flane Fit !p " Alin#ent
Flane Face
$nspected %or Cleanliness
Pipe &ore
St!ds and N!ts
Gasket
'es No
Proper FlaneMaterials and Ratin
Con%ir#ation o% Material and
$nspect General Condition
St!ds and N!t Material
St!d and N!t Condition
'es No
Condition o% Flane Face(A)rasions* rooves* r!st+
Gasket Material
Gasket Condition
(Cr!s,ed or )ent-+
A!dit o% Flane Asse#)l. Process
/ork Practice
Proper Se0!encin
/orker Trained
Proper Tools
Sa%e /ork Practices
'es No
Proper Tor0!in E0!ip#ent
Proper Ti,tness o% St!d
Co#pleted Asse#)l.Marked and $nitialed
Proper 1andlin and
Place#ent o% Gasket
E0!ip#ent 2 Spool $3 Contractor 2 Cra% ts#en4 A!ditor(s+4
Bolt Inspection and %euse
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Bolt Inspection and %euse
Procedure
The #urpose of this procedure is to assure proper inspection of boltstargeted for reuse in systems re(uiring bolt replacement) This
program is to assist in providing a 5leak free6 startup after
turnaround)
,ystems re(uiring bolt replacement will be identified on the FlangeTightening Tag) The bolts will be replaced with new and2or
inspected bolts of the re(uired type and sie)
B l I i d %
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The implementation of a 5Bolt Cleaning and .nspection ,tation6 will be
mandatory)
This station will be e(uipped with"
A bench grinder e(uipped with ade(uate safetyguards* utiliing a buffing wheel to expedite and provide
thorough cleaning for inspection on bolts larger than P6 &ia)
A
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Bolt Inspection and %euse
Procedure
All bolts to be reused in systems that re(uire replacement will beremoved and sent to the 5Bolt Cleaning and .nspection ,tation6)
The Bolt Cleaning station will inspect all received bolts for"
Bolt 5Type6 markings* re!ecting those without markings
=bvious defects* re!ecting those that are damaged)
All bolts that are re!ected are to be laid on an .nspection
bench for final inspection and accountability
Bolt Inspection and %euse
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.f no obvious defects are found"
The bolts will be thoroughly cleaned
>ubricated* with a light lubricant 8i)e)* :& @9)
Dote" Dever+seie is not to be put on the bolts at the
5Bolt Cleaning and .nspection ,tation6)
A new nut will be run by hand from one end of the bolt off
the other end
5 .f the nut does not run freely* the bolt will beconsidered to have been yielded 8i)e)* over tor(ued*
etc)9 therefore re!ected and segregated for further
inspection)
Bolt Inspection and %euse
Procedure
Bolt Inspection and %euse
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Bolt Inspection and %euse
Procedure
All bolts that are deemed acceptable by the 5Bolt Cleaning and
.nspection ,tation6 shall be placed on an .nspection bench"
,orted by sie and type
Facing in the same direction) All ends with the bolt type
stamped on them are to be faced on the same side) =nce the bolts are inspected and accepted they shall be
color coded by applying a #urple paint on the opposite
end from the stamped markings)
Bolt Inspection and %euse
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All accepted bolts will be stored in designated storage bins
segregated by the sies and types of the boltso These bolts shall be issued when the newly ordered bolting
materials are depleted)
All bolts that are re!ected by the 7C &epartment shall be
documented to show the (uantities of sies and types of the
re!ected bolts to be replaced with new ones)
o This report shall be submitted to the ,ite ,uperintendent
assuring a prompt reordering of replacement bolts asneeded)
Bolt Inspection and %euse
Procedure
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MI/IM1M %E"1I%EME/TS FO% BO-T
TE/SIO/I/. CO/T%CTO%S
7ualifications of a contractor specialiing in controlled bolt tensioningshall be addressed in the re(uest for in(uiry phase) The following
deliverables shall be reviewed and subse(uently agreed upon by
the Client* 7C -anager* and the Contractor 7uality -anager prior
to award of a contract"
7ualifications of personnel assigned to the pro!ect Dumber of craftsmen and supervision per field crew and
roles
7uality Control27uality Assurance plan
Utilities and2or e(uipment re(uirements
Tensioning Contractor approved !oint assembly anddisassembly procedures
#roposal for bolt loading when there is not enough clearance
for tensioning device
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Docu!entation %e4uire!ents 1
The Tensioning ,ubcontractor 7uality #lan shall re(uire
inspection reports2records on all tension or !oints for the
pro!ect) The .T# shall outline responsibilities for monitoring
all tensioning activities by the ,ubcontractor) .nspection reports2records should contain* as a minimum* the
designated Control >oaded Flanged Connection &ata ,heet
for each flange pair)
MI/IM1M %E"1I%EME/TS FO% BO-T
TE/SIO/I/. CO/T%CTO%S